Concrete construction.



F. M. VOGAN. CONCRETE CONSTRUCTION. APPLICATlON FILED FEB. 4, 1913.

Patented June 1, 1915.

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8 SHETSSHEET 1- attmu s F. M. VOGAN CONCRETE CONSTRUCTION APPLICATION FILED FEB. 4. 1913 1,141,671 PatentedJune 1, 1915.

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F. M. VOGAN.

CONCRETE CONSTRUCTION,

APPLICATION 1,1110 FEB. 41 1913.

Patented June 1, 1915.

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CONCRETE CONSTRUCTION.

APPLICATION FILED FEB. 4. I913.

Patented June 1, 1915.

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8 SHEETSSHEET 5- F. M. VOGAN.

CONCRETE CONSTRUCTION.

APPLICATION FILED FEB. 4, I913. 1,141,671.

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APPLICATION FILED FEB. 4. I913.

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CONCRETE CONSTRUCTION.

APPLICATION FILED FEB. 4, 1913.

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Be it known thati, FRANK Vases, a citizen of the United States, residing at -Caniton, in the county of Stark and State-of Oh-i0, have invented a new and; useful Conleaving an unfinished, uneven surface, andthen to apply a coat of plaster together with any added, molded decoration which might be desired.

Such method has proved very expensive,

and its is one of the prime objects ofjthepresent invention to cast such walls, ceilings and the like in such way that no additional plaster need be added after the. concrete has hardened, the surface of the walls and ceilings being finished at the same time said walls and ceilings are cast or molded, thus doing away with the expense, trouble and loss of time hertofore required to finish the rough-molded surfaces. A further important object of the invention is to provide knock-down forms or'surface-moldingunits preferably made of sheet metal and adapted to be connected in an appropriate relative position to produce di ferent desired surface effects and to accommodate rooms of various sizes and proportions. a

A further object is to provide knock-down means for connecting and supporting the said surface-molding units so as to reduce the carpentry and haphazard, careless and expensive work of buliding a temporary supporting structure suitable for that ar-' ticular job only, the builder, by means 0 my invented improvement being able to quickly set up the necessary supports and holding means for said units with practically no cutting or special construction of the individual two stringer-units.

of said support, said elements bemg nter-fitting, idiomchangeable peonhanly adapted for rapid, economical work with high quality of result;

In to the objects already mentioned is than to providemeains whereby the various suriae'e-Iindding unit may altered seas-to: produce various detailed ornsmmtation offthef iinis'ihed surface or to produce more For ornamentation, as may be desired.

These ob ects, i r-with other objects PW e nt to those s died in the art, may be sttaaned by the construction illustrated in the accompanying drawings, and the method bereinaiter described in connection with said drawings, although the-invention may be expressed in other forms and modes of proeedme, those illustrated and described 1 being chosen by way of example.

In the drawings Figure 1 is axperspective view of one of the longitudinal 'false stringer-units for supporting the moldur rits. Fig. 2-is a transverse sectional view of the same. Fig. 3 is a perspective view ofone of the false joist-units for spacing the stringer-units and supporting the moldunits. Fig. at is a. transverse sectional view of the same. Fig. 5 isa pers ective view of one of the joist-supporting locks. Fig.- 6 is a perspective view-of a joint-fillet. Fig. (is a'top plan viewvof the junction of a false-stringer. and two false-joists, said view also illustrating an end-coupling between Fig. 8 is a side elevation of a portion of a stringer-unit provided with a removable web-section. Fig. 9 is a perspective view or a portion of said removable web-section'. Fig. 10 is a perspective view of a cornice-supporting block.

Fig. 11 "is a perspective view of a larger cornice-supporting block for a different style of cornice. Fig. 12 is a fragmentary perspective view of-a joint-holding web. Fig. 13 is a fragmentaryperspective view of a fillersu-pporting plate. Fig. 14 is .a view principally in. perspective and partly in section illustrating false work units and mold-units assembled and arranged for the construction of a ceiling and side wall, a portion of the false work being broken away and a portion of the mold-unit broken away to more fully disclose the details. Fig. 15 is a'perspective view of a concrete wall-mold-unit spacing block. Fig. 16 is a view, partly in elevation and partly in vertical" section showing false work and mold-units of my invented con struction assembled for the construction of a concrete wall and ceiling in which the ceiling is reinforced by the use of tie rods and dove-tail-groove-plates connected thereto. Fig. 17 is a perspective view of a portion of a false stringer and a field mold-unit supporting block. Fig. 18 isa view partly in perspective and partly in vertical section showing my invention in use in the construction of a building in which the floors are fire-proofed. by hollow tile construction, also illustrating the construction of a column. Fig. 19 is an under-side perspective viewof a recessing mold-unit provided with applique, removable detailed decoration plates. Fig. 20 is a topside perspective view of asimilar mold-unit provided with a removable pendant center decoration member, the pendant-decoration member and one of the applique decoration plates being removed. Fig. 21 is a perspective view of the pendant-decoration member removed from the mold-unit illustrated in Fig. 20. Fig. 22

is a perspective view of the applique deco ration plate removed from the same figure. Fig. 23 is an enlarged fragmentary vertical sectional view through a mold-unit, such as illustrated in Fig. 20 the pendant-decoration and the applique decoration plate being attached. Fig. '24 is a plan view of a portion of a concrete ceiling constructed by means of and in accordance with my invented improvement.

Throughout the several views similar reference numerals indicate similar parts.

In a preliminary and general way it may be stated that my invention contemplates sheet metal mold units embossed with the design which it is desired to impart to the surface of the concrete wall or ceiling to be cast, the marginal edges of each mold unit being bent outwardly, away from said surface to afford means for holding said unit in position upon the supporting false-work. Said mold units are preferably made in predetermined standard sizes adapted to fit together in various combinations and said false-work is also made up of standardized units provided with means for receiving and holding the said out-turned marginal edges of the mold units. It will be understood that the standard lengths and sizes of the false-work mus tcorrespond to the standard dimensions of the mold units in order that said false-work may be readily set up to receive the mold units in various desired combinations.

With the above preliminary statement it should be also noted that in the further and more specific description of the invention reference will first be made to the construction of the false-work units and the assembling thereof, then the mold units, and finally the use of said mold units with the false-work and the method of concrete construction employed therewith will be fully Connected to the stringer base 1 is the vertically extending stringer web 2 preferably formed of two up upon one edge.

Extending along the upper free edge of the web 2 is a compound slot comprising the shallower, broader joint-bead forming portion 3 and the mold margin receiving portion 4 extending from the bottom of the portion 3 deeper into the web and being narrower than the portion 3 so as to produce oppositely disposed off-sets or shoulders 5. In order to provide against rapid wear the slot is preferably provided with a sheet metal lining 6, the edges 7 of said lining bein'g countersunk into the edge of the web 2. I

At predetermined equal intervals of spacing along the web 2 are transverse mold juxtaposed timbers set joint notches 8 corresponding in cross sectional shape to the cross sectional shape of the. longitudinally disposed "slot just described and on both sides of the web 2 adjacent said notches are pairs of joist holdcompound slot of the same cross sectional shape and size as the slot in the stringer web just above described. The parts of the slot in the joist units illustrated are numbered the same as the parts of the slots of the stringer units. The joist base is preferably not formed in the same manner as the stringer base, but is formed by two joist base-strips 12 fixedly connected to the lower side edges of the webs 11. The joist web at both ends of the oist unit extends slightly beyond the ends of the joist base, and the said ends of the web are rounded, as shown in Figs. 3 and 7, for the purpose hereinafter pointed out. At each end of the joist is also arranged a transverse spline member 13 provided with a rounded upper edge adapted to fit into the upwardly curved grooves in the blocks 9 above described.

The upper edge of each spline member 13,

it will be understood, is' above the upper.

surface of the joist base-strips 12.

It should be stated at this point that the two blocks 9 of each pair are spaced from each other just the necessary distance to receive between them the web 11 Ma joist unit and the upper edge of the spline member 13 with relation to the upper edge of the web 11 is such that when the upper edge of said web 11 is raised to coincide with the upper edge of the web 2 of one of the stringers the said spline 13 will engage the grooves in the blocks 9 The height of the webs 11 is less than the height of the webs 2 so that a joist unit may be arranged with its base on top of the base 1, the web 11 extending at right-angles to the web 2 and the end of the joist unit may then be moved along upon the base 1 until the proper. relative position with the blocks 9 has been reached, whereupon the joist unit may be raised until the said spline 13 engages the grooves in the blocks 9, and a joist supporting block 14 may then be arranged between the underside of the base of the joist unit and the top side of the base. 1 of the stringer unit to support said joist unit and hold it in firm engagement with the stringer unit. When in this position it will be understood that the compound slot of the joist unit registers-with the mold joint notch 8 in the stringer unit, as shown clearly in Fig. 7.

It will be understood that in setting up falsework in accordance with my invention a plurality of stringer units will beplaced in parallel and equally spaced arrangement and a plurality of joist units will then be employed to connect the various stringer units, said joist units extending transversely with reference to said stringer units.

To provide for removing a single mold unit for the purpose of inspecting the condition of the work after the concrete has been, cast some of the stringer units are provided with removable web sections, such as illustrated in Figs. 8 and 9. It will be noted that the removable web section, which is numbered 15, is of less "ertical dimension than the web section 2 and is,- in fact,-of the same vertical dimension as the joist webs 11. Each removable web section.

is of such length as to extend from center to center of adjacent mold joint notches 8, the ends of the removable section being provided with notches as at'-l6 corresponding in shape to one-half of the cross section of one of the notches 8. Each web section is also provided with a block 9 and a block 10 adjacent each end so that when the removable section is in place, as shown in Fig. 8, and supported upon the base 1 by means of the supporting blocks 17 similar to the joist supporting block 14, the arrangement ofmold joint notches 8, blocks 9 and blocks 10 will be uniform throughout the length of the stringer. The practical reason for this construction will be more evident as the description proceeds.

In the construction of ceilings it will usually be found desirable to provide sheet metal mold units which, throughout their greater extent, will require support in order to sustain the great weight of the plastic concrete cast upon them. It will hereinafter more fully appear that the edges of such mold units will be sufficiently supported by the stringers and joists. For the purpose of supporting the body of such units however the supporting block illustrated in perspective in Fig. 17 is provided. This block consists of the mold holding member 18 and the cross members 19 which are of sufficient length to extend from one stringer to the other. The said cross members 19 extend parallel to each other and are sufliciently separated so as to engage the inner sides of adjacent blocks 10 of the stringer, a supporting block 20 being arranged underneath the members 19 to hold the same in proper elevated position. In Fig. 16 the members 19 are clearly shown in position supporting the mold units, the under surfaces of said members 18 being substantially in alinement with the upper'edges of the stringer and oist webs.

In setting up the false-work for'the construction of the Walls and ceiling of a room a heavy supporting frame must be provided, the cross beams 21 of which are adapted to receive and support the false stringer units which extend transversely with relation to said beams. The beams 21 extend substantially to the side walls of the room and at the side walls are the beam supporting and wall framing vertical units 22. Said vertical units are substantially the same in construction as the stringer units hereinbefore described and are provided with webs 2 and base portions 1 similar to the corresponding parts of the stringerunits.

As an illustration of one type of ceiling which it is convenient to construct in accordance with my invention attention is called to Fig. 21. Therein it will be noted that the field of said ceiling is formed of a plurality of square panels 23, the outer row of panels around the room being provided with egg and dart decorative molding and the central portion of each panel being depressed. In Fig. 2% the panel inside of the outer row is shown without the decorative molding and it will be understood that such panels may be formed in such plain fashion or decorated as may be desired. Between the panels extends a portion 24 in high relief which may be termed the frame portion and which not only extends between the various panels, but also externally with relation to the outer panels and terminates outwardly in an eg and dart molding 25 leading up to thefil er 26 the outer edge of which is at the upper part of the cornice 27, which is provided with egg and dart and other molding decorations "to appropriately connectthe ceiling with the side wall.

From an inspection of Figs. 14 and 16 it will be noted that the field 26 is supported.

upon the fillersupporting plate 28, which is of the form illustrated in Fig. 13, said plate being provided at regular intervals throughout its length with transverse slots provided with joint-bead'-forming portions and mold margin receiving portions of the same cross sectional shape as the slots in the stringer web hereinbefore described. To support the joint between the mold unit forming the field 26 and the mold unit forming the cornice 27 a stringer unit 29 provided with an extra high web portion is provided. For the purpose of supporting the cornice mold units in designs of the character illustrated in Figs. 14, 16 and 24 the cornice supporting blocks 30 especially illustrated in Fig. 10 are provided. These blocks are formed to fit the outline of the cornice and are provided with an edge slot at 31 of the same cross sectional shape as the slot in the stringer web, the slots at 31 being adapted to receive the end edges of the cornice mold units. Each cornice supporting block is also provided with a spline member 32 adapted to fit into the upwardly rounded notches of the blocks 9 arranged upon the adjacent stringer web.

In Fig. 11 isshown a cornice supporting block of a different shape and size, the same being adapted fora cornice of different outline. It will be understood that such cornice supporting blocks may be of any design necessary in accordance with the particular cornice design adopted.

Referring now to the mold units, it will be understood that the same are stamped from sheet metal and an inspection of Fig. 19 will give an understanding of the form of said units designed for the molding of the various panels forming the field of the ceil- 'ing, such as illustrated in the outer row of panels in Fig. 24. Each panel unit of this kind is formed exactly square and is provided with a joint-bead-forming compound flange 33, illustrated in a number of the figures of the drawings, and with a marginal holding flange 34. Two opposite edges o each panel mold unit are let into the slots of adjacent stringers and the other two opposite edges are let into the slots of adjacent joist units, it being understood that the mold holding member 18 should be also used to support the panel as well illustrated in Figs. 16 and 18. If desired the compound flanges 33 fitting into the joint-bead-forming portions 3 of the slots may be left open to form a joint-bead in high relief in the molded surface, or a joint fillet 35 comprising a strip of material such as illustrated in Fig. 6 may be arranged as illustrated in Figs. 14, 16 and 18 to fill the said space and prevent the molding of such a joint-bead.

It will be understood that the filler mold units 36 are provided at both lateral and end edges with compound and holding flanges of the same character as just described, the inner lateral edges of said units 36 being provided with a molding portion 37 adapted to complement the outer molding portions of the panels of the field to produce the finished effect illustrated in Fig. 24.

In the practical carrying outof my invention the mold units for the field panels should be put in place with as great nicety and exactness of measurement as possible, then the cornice units should be arranged in place, and the outer edges of the filler units may then be cut and bent as may be necessary to fill the space required. In this way any variation in measurement or arrangement may be conveniently taken care of in the plain portion of the filler, the surface of said fillerbeing preferably only slightly embossed as for example illustrated in Figs. 14 and 2.4.

The mold units for the side walls are made in panels or sections as illustrated in Figs. 14 and 16, the four edges of each section being provided with compound and holding flanges 38 and 39 respectively similar to the similarly named flanges of the other mold sections hereinbefore described. Running horizontally and supported by the units 22 are the wall joist units 40 provided with slots similar to the slots in the joist units of the ceiling and receiving the horizontal edges of the wall mold units as clearly illustrated in Figs. 14 and 16. The vertical edges of the wall mold units are located in the slots of the vertical units 22 as the longitudinal edges of the ceiling mold units are located in the stringer units.

As illustrated in Fig. 16 it will be noted that the wall is cast between oppositely disposed spaced wall mold units which are held in spaced relation by concrete spacing blocks 41. From the illustration of one of said blocks in Fig. 15 it will be noted that same consists of a cylinder of concrete provided with a central longitudinal bore adapted to hold the tie bolts 42 illustrated in Figs. 14 and 16. The ends of the spacing blocks are preferably conical so as to enable the concrete forming the wall proper to flow around the ends of said blocks and thereby produce the least possible marring of the surface of the finished concrete after the molds have been removed from the wall. It will be understood that the tie bolts 42 necessarily produce apertures through the wall after the wall mold units have been removed and it is desirable that such apertures and the adjacent surfaces of the wall be as slightly marred as possible by the filling and retouching made necessary by such apertures. One of the principal purposes of the tie bolts 42 is to draw the wall mold holding blocks 43 firmly into position to support the wall mold units, as is clearly illustrated in Figs. 14 and 16.

After the ceiling and wall mold units have been properly arranged and" connected as described and illustrated the plastic concrete is poured from above between the wall mold units and on top of the ceiling mold units and permitted to harden. When the concrete has sufliciently set and hardened the false-work units as well as the mold units may be removed section by section and again used at other places in the same or different combinations.

My invention. it will be noted, is applicable to various types of building construction. In Fig. 14 I have shown a purely concrete construction while in Fig. 16 I have shown a construction in which I-beams 44 together with dove-tailed reinforcing strips 45 of sheet metal strung upon suspending rods 46 connected to said I-beams are provided. Said reinforcing members preferably extend transversely from I-beam to I-beam along the line of and seated within the high relief frame portions between the various panels of the ceiling and the concrete 17 below said reinforcing member may be of finer quality than the concrete 48 above if desired.

In Fig. 18-I have illustrated a fire-proof block construction in connection with my invention. In this figure it will be noted that the I beams 49 support between them the fire-proofing blocks 50 which are set on top of the concrete 51 after it has been poured upon the ceiling mold units. The construction may then be finished on top by a top coating of concrete 52 if desired. In the same figure it should be noted that the reinforcing rods 53 extend through the concrete 51 in the thicker portions thereof.

My invention is clearly applicable to various other types of modern construction.

Attention is called in Fig. 18 to the column 51 which is formed by sheet metal mold units 55 provided with the marginal, out-turned connecting flanges 56. Said column may if desired be constructed in accordance with the disclosure in my United States Patent on sheet metal manufacture No. 1,056,072, issued March 18, 1913, and the concrete forming said column may be poured into the mold at the same time that the concrete 51 is applied.

It will be understood that in carrying out my invention the concrete first applied to the mold unit surfaces should be of finer quality than is necessary for the internal or body portions of the structure. This is for the purpose of producing a finer and more elegant surfacein the finished wall or ceiling and for the purpose of more faithfully reproducing every detail of decoration embossed in the mold units.

As for instance in the field-panel mold units such as illustrated in Fig. 19, it is sometimes desirable to change the detail decoration, as from the egg and dart pattern to that of some other pattern of molding. In order to provide not only for the convenient and ready change of decoration without requiring the entire mold unit to be changed or replaced, but to provide for the making of the ornamental portions of the mold units from sufliciently thin material to properly draw under the drop hammers so as to produce sharp and distinct and even and perfect lines and also for the purpose of the ready removal of the deeply stamped decorative portions of the molds from the finished molded surface, I provide applique decoration members stamped from comparatively thin material and adapted to be applied to the heavier mold units. In

Fig. 20 is shown a mold unit from which one of the appliqu molding members has been removed. Said member is shown in Fig. 22 and will be seen to comprise merely a strip of material embossed with the decoration desired and provided with apertures 57 adapted to register with apertures 58 in the mold unit to provide for fastening means, such as bolts or rivets to fasten the applique members to the mold unit. Without the appliqu members such a mold unit would produce a. panel such as the plain or undecorated panel illustrated in the lower right-hand corner of Fig. 24. With the appliqu members connected to the mold section however the egg and dart decoration illustrated in the other panels of Fig. 24 will be produced. In removing the mold sections from the finished concrete surface, where the decoration involves deep indentations or high projections it may be desirable to disconnect the appliqu members from the mold sections before removing the mold section itself. Then the mold section may be removed and the appliqu members removed one by one, said members being sufficiently thin to be bent and warped to remove them from the decorated surface without injury thereto.

I claim 1. For concrete construction the combination of a pluralityof mold units adapted to be contiguously arranged and provided with out-turned flanges at all edges thereof and a plurality of false-work units adapted to be connected together in arrangement corresponding to the arrangement of said marginal flanges of said mold units and provided with slots adapted to receive said marginal flanges, whereby to connect and support said mold units.

2. For concrete construction the combination of a plurality of sheet metal mold units provided with mold faces and with outturned marginal flanges, certain of said units contiguously arranged and disposed with their mold faces in a horizontal plane to cast a ceiling and certain of said mold units contiguously arranged with their mold faces in a vertical plane to cast a side wall, false-work units connected together in arrangement corresponding to the arrangement of the marginal flanges of the mold units for casting the ceiling and provided with slots adapted to receive said marginal flanges and a plurality of false-work units connected together in arrangement corresponding to the arrangement of the marginal flanges of the mold units for casting the side wall and provided With slots adapted to receive said marginal flanges, certain units of the false-work for the side wall supporting the false-work units for the ceiling.

3. For concrete construction, in combination with sheet metal mold units having outturned flanges at all edges thereof, false stringer units and false joist units supported by said stringer units, said stringer units and joist units provided with slots adapted to receive said flanges.

4. For concrete construction, the combination of rectangular sheet metal mold units provided with out-turned flanges at all edges thereof and parallel false stringer units and parallel false joist units transverse to and supported by said stringer units, said stringer units and joist units provided with slots adapted to receive said flanges.

5. For concrete construction, in combination with sheet metal mold units provided with marginal flanges at all edges thereof,

false stringer units provided with flange receiving slots and transverse mold joint notches and false joist units disposed transversely with reference to said stringer units and provided with flange receiving slots, the slots of said joist units registering with said notches to continue the slots of said joist units into the slots of the stringer units.

6. 1 or concrete construction, in combination with a rectangular sheet metal mold unit provided with out-turned marginal flanges at all edges thereof, parallel false stringer units provided with vertically disposed web portions having longitudinally disposed flange receiving slots in their free edges and transverse joint notches opening from said slots through the sides of said web portions, grooved oist holding blocks connected to said web portions adjacent said joint notches, transverse false joist units provided with web portions and longitudinally disposed flange receiving slots therein, said joist units arranged transversely with reference to said stringer units, with the flange receiving slots of said joist units registering with the joint notches in said stringer units, means connected to said joist units and seated in the grooves of said joist holding blocks to connect said stringer units and joist units together, and the flanges of said mold units arranged in the said slots and notches of said stringer units and joist units. I

In testimony that I claim the above, I have hereunto subscribed my name in the presence of two witnesses.

FRANK M. VOGAN. Witnesses: WILLIAM H. MILLER,

JOHN H. BISHOP. 

